Method and device for packaging a product in a wrapper of sheet material

ABSTRACT

A method and a device for packaging a confectionery product (P) in a shaped wrapper of sheet material ( 1, 2 ) having a cup-shaped portion ( 1   c,    2   c ) (pleated cup) formed from the same sheet material as the product wrapper; the method and the device comprise the use or a mandrel with petals ( 14   a,    14   b ) which cooperates with a forming cavity ( 11 ) and which may assume a retracted configuration so that it can penetrate into the forming cavity to shape the wrapper into a cup shape adhering to the product. The packaging is characterized in that the wrapper has a central region ( 2   a ) on which the product bears and from which the cup extends with a transverse dimension (or diameter) smaller than the maximum transverse dimension of the packaged product.

The present invention relates to a method and a device for packaging aproduct, in particular a confectionery product such as a praline or achocolate, in a wrapper of sheet material.

The invention also relates to a packaging obtained by the method of theinvention.

In the confectionery sector, it is conventional to package individualproducts, such as a praline, for instance, in a wrapper of sheetmaterial which tightly encloses the product and then to insert thewrapped product in a cup of sheet material with a pleated peripheralwall (hereafter known by the appropriate term of “pleated cup”) in orderto present it in a more pleasing and attractive way. The term “pleatedcup” as used in the present description does not however imply that thecup must have a pleated wall.

When the product is being packaged, this solution requires separate anddistinct operations to obtain the pleated cup, wrap the product in itswrapper and insert the wrapped product in the pleated cup, possibly withan additional operation to attach the pleated cup to the base of thewrapped product by adhesion.

In order to reduce the number of packaging operations included in theconventional technique used in the confectionery sector and to obtain apackaging similar to the conventional packaging, EP-A-1 046 579describes a method and a device for its provision in which the pleatedcup is an integral part of the product packaging wrapper.

In particular, EP-A-1 046 579 describes a method comprising theoperations of:

-   -   obtaining an intermediate packaging, including a first sheet        having a cup-shaped configuration, with a container wall        including the product and a mouth surrounded by a radial flange        formed by a peripheral region of this first sheet, and a second        sheet having a central region disposed to cover the mouth and a        peripheral region disposed in a superimposed relationship with        respect to the peripheral region of the first sheet forming the        flange; and    -   shaping these peripheral regions of the intermediate packaging        in order to form a wrapper portion shaped as a pleated cup which        surrounds the container wall of the first shaped sheet at a        radial distance, by means of shaping means which comprise a        forming cavity able internally to receive the intermediate        packaging and a male member, in the form of a punch, able to        penetrate into the forming cavity in order to force the        peripheral regions of the first and second sheets between the        inner surface of the forming cavity and the outer surface of        this male member.

Prior to the final shaping operation of the peripheral regions of thefirst and second sheets, these peripheral regions are preferably sealedtogether, for instance by adhesion with the application of fillermaterial, heat sealing or ultrasonic sealing so that the product ispackaged in a hermetic wrapper having the configuration shown in FIG. 8of EP-A-1 046 579.

By means of the method described above, in particular in cases in whichthe product has an ovoid or spherical shape, or a shape in which thedimension of its base is smaller than its maximum transverse dimension(or its maximum equatorial dimension in the case of products ofspherical shape), it is difficult to ensure that the connected wrapperof sheet material, which forms the pleated cup, tightly wraps theproduct in its region facing the base of the pleated cup. This may raisea problem of air pockets in the hermetic wrapper and may in particularraise a problem of an aesthetic nature as the packaging is not able toreproduce the same aesthetic effect as produced by the insertion of awrapped product in a separate pleated cup according to the conventionaltechnique.

The present invention is intended to improve the method and the devicedescribed in the above-mentioned European Patent Application and paysparticular attention to the problem of ensuring that the connectedwrapper sheet material which forms the pleated cup tightly encloses theproduct. Moreover, the invention has been devised with a view toproviding a packaging which—from an aesthetic point of view—has featuresentirely similar to conventional packagings of a hand-made nature.

In view of these objects, the invention relates to a method, a deviceand a packaging having the characteristic features set out in theappended claims.

The invention will now be described, purely by way of non-limitingexample, with reference to the appended drawings, in which:

FIGS. 1 to 4 diagrammatically show, in sequence, the initial stages ofthe method by which the intermediate packaging is obtained, according tothe teaching of EP-A-1 046 579, which packaging is adapted to be subjectto the final shaping stages according to the characterizing features ofthe present invention;

FIGS. 5, 6 and 7 diagrammatically show, in succession, the operationalstages of shaping of the intermediate packaging according to thecharacterizing features of the present invention;

FIG. 8 is a sectional view of an elementary member, given purely by wayof non-limiting example, for the application of the method of theinvention; and

FIG. 9 is a sectional view of a packaged product produced by the methodof the invention.

In essence, the stages shown in FIGS. 1 to 4 do not differ substantiallyfrom the stages shown in the corresponding FIGS. 1 to 4 of EP-A-1 046579. However, the method of the invention should not be considered to belimited to the reproduction of these operating stages, as it may beapplied to pre-shaped packagings having features similar to those shownin FIG. 4, however they are obtained.

In the embodiment described, the product to be packaged, shown by P, isformed by a praline of overall spherical shape, the outer surface ofwhich may—as shown—have an overall irregular appearance, due to thepresence of an outer coating formed, for instance, by chopped nuts,grated coconut or granules of meringue. The invention may neverthelessbe applied to products of different shape, for instance products ofovoid or elliptical shape, as well as products of frustoconical orfrustopyramidal shape, adapted to be packaged with their smaller sidefacing the base of the pleated cup or to products with a frustoconicalor frustopyramidal body provided with a dome on the side opposite theirsmaller side which may be spherical, ovoid, elliptical or of mixedgeometric shape.

In order to form a leak-tight wrapper about the product P, two sheets 1and 2 of aluminium or other laminar material are used. The choice ofother laminar materials includes for instance the use of pairings ofaluminium with composite films of plastics barrier material withthermofusible films or sheets of aluminium covered with a lacquer,preferably of a thermofusible type.

The first sheet, shown by 1, generally has dimensions which are muchlarger than those of the sheet 2.

The first step of the operation to package the product P comprises anoperation to shape (possibly by drawing) the sheet 1 into a general cupshape with a container wall comprising a dome region 1 b, a collarregion 1 a and a radial flange 1 c defined by the peripheral region ofthe sheet 1. This operation may be carried out by means of a toolcomprising a mould 3, which has a cavity 3 a within it, into which apunch 4 having a surface 4 complementary with the inner surface of thecavity 3 a may penetrate.

In general, the cavity 3 a has a depth such that, once it is shaped as acup, the sheet 1 is able internally to receive the product P more orless integrally; this solution should not, however, be consideredimperative as it is also possible to envisage the case in which theproduct may project slightly above the opening mouth of the cup-shapedsheet 1.

In the operating stage of FIG. 3, the product P has been positionedwithin the cup-shaped sheet 1 and the sheet 2 with its central region 2a covering the mouth of the cup and its peripheral region 2 csuperimposed on the peripheral flange region 1 c of the sheet 1.

In the arrangement shown, in which the sheet 1 has been shaped so thatit is able internally to receive substantially all of the product P, thesheet 2 is simply placed on the upper portion of the product P thuskeeping its original planar shape, both in its central region 2 a and inits peripheral region 2 c. However, in the case in which the productprojects slightly outwards from the mouth portion of the cavity 3 a, thecentral region 2 a of the sheet 2, positioned above the product, mayassume, as a result of its flexibility, a curved configuration; it isalso possible to envisage the case in which the central region 2 a ofthe sheet 2 is pre-shaped with a cup configuration adapted to receivethe projecting portion of the product P.

In the operating stage of FIG. 4, a tool 6 is used to seal (and possiblyalso cut) the sheets 1 and 2 at their respective counterpart peripheralregions 1 c and 2 c.

The sealing of the two sheets is adapted to ensure that the sheetwrapper provided about the product P is leak-tight. However, although itis preferable to connect the two sheets, it is not imperative for themto be sealed in a leak-tight manner.

To provide this seal, it is possible for instance to use adhesion—withadded material—or heat sealing carried out preferably by promoting thefusion (by direct heat provision or the application of ultrasonicvibrational fields) of a thermofusible coating (lacquer) or athermosetting material provided on the inner surfaces of the sheets 1and 2.

The operation to cut the peripheral regions 1 c and 2 c which may besealed together may be carried out by a punching tool, whose cuttingedge, shown by 6 a in FIG. 4, extends along a trajectory (which iscircular in the embodiment shown) following the outer edge of the mouthwall of the cavity 3 a.

FIGS. 5 to 7 show the operating stages for shaping of the pleated cup“integral” with the wrapper. This operation is carried out by means of ashaping device 10 comprising a moulding (or forming) cavity 11 and amale member 14 in the form of a punch.

The cavity 11 has a general tapered shape between an insertion openingor mouth 12 and a discharge opening or mouth 13 whose dimensions aresmaller overall than the dimension of the insertion mouth 12.

Normally, the above-mentioned openings and the tapered wall of themoulding cavity 11, which extends to their junction, have a generalribbed profile so as to provide cross-sections which are, so to speak,stellate or pleated and characteristic of pleated cups. The profile ofthe wall connecting the insertion opening 12 and the discharge opening13 may be rectilinear (frustoconical or frustopyramidal cavity) but mayalso be curved.

This means that the sectional profile of the moulding cavity 11 isadapted to the features of the product P and should not therefore beconsidered to be limited to a circular cross-section, as shown in thedrawings.

Similarly, the wall 18 connecting the insertion opening 12 and thedischarge opening 13 is preferably grooved so as to provide a pleatedcup with a pleated lateral wall, but may also be smooth and may havesmooth surface portions and grooved portions in a predeterminedarrangement.

Preferably, the forming cavity 11 comprises a radial shoulder 15 adaptedto bear the peripheral portions 1 c and 2 c of the wrapper sheets.

According to an innovative feature of the method and the device of theinvention, the male member 14 comprises a petal mandrel whose petals maymove radially between an extended position and a retracted position.

In the diagrammatic cross-sections of FIGS. 5 to 7, two petals 14 a and14 b are shown, but it will be appreciated that the mandrel could beformed by a plurality of petals (for instance from three to six petals),typically four, depending on the dimensional features of the product P.

In the case of four petals, each petal extends radially over an angularamplitude of approximately 90°. Each petal has a tapered end portion 16converging towards the axis a-a of the mandrel in the direction of thearrow F₃ (FIG. 6), which—in the retracted configuration of themandrel—is able to penetrate into the forming cavity 11 and has atapered radially outer surface 17 substantially complementary with acounterpart portion of the wall 18 of the forming cavity 11.

The outer surface 19 of the end portion 16 is also tapered and convergestowards the axis a-a of the mandrel in the direction of the arrow F₃.

The outer surface 17 of the end section 16 of the mandrel which, asmentioned above, is complementary with a counterpart portion of the wall18 of the forming cavity 11 will preferably therefore be ribbed.

The petal mandrel 14 may move axially relative to the forming cavity 11between a position spaced from this cavity, in which the petals of themandrel are in the extended configuration, able to encompass thecontainer wall 1 a of the wrapper, and a forward position in which thetapered end of the mandrel has penetrated into the forming cavity 11 andthe petals 14 a, 14 b are in the retracted position. The relativemovement of the mandrel 14 with respect to the forming cavity 11 takesplace under the action of motor means (for instance linear actuators)which are not shown in FIGS. 5 to 7 as they are known per se.

It will be appreciated that the reference to a relative movementincludes the case in which the mandrel may move with respect to thefixed forming cavity, and the opposite case in which the forming cavitymay move with respect to a fixed mandrel, as well as the case in whichboth may move with respect to one another.

The motor means may therefore be associated with either the mandrel orthe forming cavity.

FIG. 5 shows an initial position, in which the mandrel 14 is spaced fromthe forming cavity, with the petals in the extended position, and theintermediate packaging in which the product P is wrapped by the twosheets according to the configuration shown in FIG. 4, is positionedabove the forming cavity 11. In this position, a support member 20,comprising a rod 21 and a plate 22, supports and bears the centralregion of the wrapper 2 a.

The rod 21 may move axially and is adapted to be gradually retractedfrom the inside of the forming cavity in a coordinated manner with thepenetration action of the mandrel 14, supporting, during this movement,the base of the wrapped product P. For that purpose, the rod 21 may beconfigured in the form of a take-up member, for instance by vacuum, asit has a longitudinal internal duct 23 which communicates at thelocation of the plate 22 and is connected on the opposite side to asub-atmospheric pressure source so as to ensure that the wrapped productP received is held on the plate 22 and follows this plate during themovement of penetration into and/or extraction from the forming cavity11.

Optionally, the shaping device 10 further comprises a support and/orthrust member 24 which may move in a linear manner with respect to theforming cavity 11 and has a seat 25 complementary with the end crownportion 1 b of the wrapper. The linear movement of the support and/orthrust member 24 is coordinated with the linear movement of the rod 21in order to cause the wrapped product P to penetrate into the formingcavity 11.

FIG. 6 shows the position in which the thrust member 24 engages thecrown 1 b of the wrapped product P and in which the petals 14 a, 14 bare in the extended position, encompassing the greater dimension of thewrapped product.

FIG. 7 shows an intermediate position, in which the wrapped product Phas partially penetrated into the forming cavity 11 and the petals 14 a,14 b have been progressively actuated in the direction and way of thearrows F₁ and F₂ towards their end retracted position by means ofactuator means (not shown).

After the petal mandrel 14 has penetrated into the forming cavity 11,the peripheral regions 1 c and 2 c of the intermediate packaging areshaped into the desired pleated cup configuration, shown in FIG. 9,which configuration is stable as a result of the general plasticbehaviour of the sheets 1 and 2.

In a preferred embodiment, the forming cavity 11 may be heated and thenpossibly cooled as heating and possible subsequent cooling improve thestability of the pleating. For that purpose, a short dwell time in theend forming position may be provided, which dwell time may be selectedas a function of the properties of the sheet material used.

The packaging may be discharged from the forming cavity 11 either viathe smaller opening 13 (previously defined as the discharge opening) asa result of the drawing action that the plate 22—(by means of thesuction duct 23)—exerts on the wrapper, or through the opening 12(previously defined as the insertion opening). In this latter case, itwill be appreciated that the removal of the packaged product takes placeafter the mandrel 14 has been returned to the position spaced from theforming cavity 11.

With reference to the final packaging shown in FIG. 9, it will be notedthat as a result of the actuation of the petal mandrel, in the retractedposition, the wall 1 a of the sheet 1 is closed up to the outer surfaceof the product as a result of which the adhesion of the wrapper and inparticular of the sheet 1 to the outer surface of the product P isimproved. It will also be noted that the transverse base dimension ofthe pleated cup (diameter) shown by Φ₁ in FIG. 9, is smaller than themaximum transverse dimension Φ₂ of the wrapped product P.

By appropriate shaping of the end portion 16 of the petals 14, it isalso possible further to improve the adhesion of the wall 1 a to thewall of the wrapper with respect to what is shown purely by way ofexample in FIG. 9.

FIG. 8 is a sectional view showing a detail of a device for theimplementation of the packaging method described above.

In FIG. 9, those members corresponding to the members shown in FIGS. 1to 7 bear the same reference numerals.

It will in particular be noted in the example of FIG. 8, given purely byway of example, in order to describe a basic actuation system for amandrel, that the petal mandrel 14, and the member 24, may move upwardsin the direction of the forming cavity 11. The member 24 acts as asupport and thrust member and is adapted to cause the intermediatepackaging to penetrate into the forming cavity 11.

Each petal 14 a, 14 b (at least four petals are also to be preferred inthis case) is connected to at least one cursor 25, 26 sliding in arespective slot 27, 28 which—in the direction of forward movement of themandrel 14 towards the forming cavity 11—comprises a section 27 a, 28 aconverging towards the longitudinal axis of the mandrel 14. In this way,the forward movement of the mandrel towards the forming cavity by meansof motor means (not shown) causes the actuation of the petals into theirretracted position.

The slots 27 and 28 thus have a rectilinear terminal section in whichthe respective cursor 25, 26 may move in order to cause the removal ofthe shaped product P upwards through the discharge opening 13 of theforming cavity 11.

As mentioned above, the lateral wall 1 c, 2 c of the pleated cup,integral with the packaging, is preferably a pleated wall. In order toobtain the best results and optimize the shape of the pleated cup, thepleating pitch of the wall of the forming cavity 11 and thecomplementary outer surface of the petal members (i.e. the distancebetween two successive ridges) is calculated as a function of the basediameter Φ₁ of the pleated cup and the conical nature of the formingcavity 11 so as to ensure that the pleated wall is free fromsuperimpositions and wrinkles and is radiated and well extended.

It will be appreciated that the choice of these parameters in order toachieve the best result is among the skills of a person skilled in theart.

As indicated in EP 1 046 579, whose specification is considered to beincorporated into the present specification as a result of its citation,the method of the invention may be applied either with sheets 1 and 2formed by the same material and/or having identical chromatic features,or with sheets formed by different materials and/or having differentchromatic features.

Naturally, the principle of the invention remaining the same, the formsof embodiment and details of construction may be varied widely withrespect to those described and illustrated, without thereby departingfrom the scope of the appended claims.

1-22. (canceled)
 23. A method for packaging a product in a shapedwrapper of sheet material, comprising the operations of: obtaining anintermediate packaging, including a first sheet having a cup-shapedconfiguration, with a container wall including the product and a mouthsurrounded by a radial flange formed by a peripheral region of saidsheet, and a second sheet having a central region disposed to cover themouth and a peripheral region disposed in a superimposed relationshipwith respect to the peripheral region of the first sheet forming theflange, and shaping said peripheral regions of the intermediatepackaging in order to form a wrapper portion shaped as a cup whichsurrounds the container wall of the first shaped sheet at a radialdistance, by means of shaping means which comprise a forming cavity ableinternally to receive the intermediate packaging and a male member, inthe form of a punch, able to penetrate into the forming cavity in orderto force the peripheral regions of the first and second sheets betweenthe inner surface of the forming cavity and the outer surface of saidmale member, characterized in that the male member in the form of apunch comprises a petal mandrel whose petals may move between a radiallyextended position in which the petals are able to encompass thecontainer wall of the intermediate packaging and a retracted position inwhich the petals are able to penetrate into the forming cavity so as toform the cup formed by the radial flanges adhering to the product.
 24. Amethod according to claim 23, characterized in that the petals have atapered end portion converging towards the axis of the mandrel in thedirection of penetration of the mandrel into the forming cavity.
 25. Amethod according to claim 23, characterized in that the tapered endportion comprises a radially inner surface tapered in a directionconverging towards the axis of the mandrel.
 26. A method according toclaim 23, characterized in that the intermediate packaging is obtainedby a method comprising the stages of: providing a first and a secondsheet of wrapping material, shaping the first sheet into a cup-shapedconfiguration able internally to receive the product, inserting theproduct into the first sheet shaped in this way, applying the secondsheet to the opening mouth of the first cup-shaped sheet, and connectingthe counterpart peripheral regions of the first and the second sheets inorder to form a wrapper substantially closed about the product.
 27. Amethod according to claim 23, characterized in that the first and thesecond sheets are sealed together by a sealing operation selected fromthe group including: gluing with the application of added material, heatsealing, and ultrasonic sealing.
 28. A method according to claim 23,characterized in that it comprises the operation of coating the firstand the second sheets with a layer of thermofusible material at thelocation of the surfaces to be connected.
 29. A method according toclaim 23, characterized in that the operation to shape the peripheralregions of the intermediate packaging is carried out by subjecting thesheet material to heating and possibly then to cooling, in the formingcavity, in order to maintain the shape of the cup and the relativepleats faithful to the shape of the forming cavity.
 30. A methodaccording to claim 23, characterized in that the peripheral regions ofthe first and second sheets are shaped as a cup with a pleated wall. 31.A shaping device comprising a forming cavity having a forming wall and amale member, in the form of a punch, having a forming surfacecomplementary with the forming wall of the forming cavity able topenetrate into the cavity in order to shape a sheet material interposedbetween the forming wall of the forming cavity and the forming surfaceof the male member, characterized in that the male member comprises apetal mandrel which may move in a linear manner relative to the formingcavity and whose petals may move between an extended position and aretracted position in which they may penetrate into the forming cavity.32. A device according to claim 23, characterized in that it comprisesactuator means adapted to cause the actuation of the petals between theextended position and the retracted position during the stroke of themovement of penetration of the petal mandrel into the forming cavity.33. A device according to claim 23 for packaging a product in a shapedwrapper of sheet material from an intermediate packaging comprising afirst sheet having a general cup-shaped configuration with a containerwall in which the product is housed and a mouth surrounded by a flangeformed by a peripheral region of the first sheet, and a second sheethaving a central region disposed to cover said mouth and a peripheralregion disposed in a superimposed relationship with respect to thecounterpart peripheral region of the first sheet, wherein the devicecomprises shaping means comprising: a forming cavity adapted internallyto receive the intermediate packaging, a male member, in the form of apunch, moving relative to the forming cavity in order to penetrate intosaid forming cavity, so as to force the counterpart peripheral regionsof the first and second sheets between the inner surface of the formingcavity and the outer surface of the male member in order to shape saidcounterpart peripheral regions into a cup configuration surrounding thecontainer wall of the first sheet at a radial distance, characterized inthat the male member comprises a mandrel with petals, whose petals maymove between a radially extended position able to encompass thecontainer wall of the first sheet and a retracted position in which thepetals are able to penetrate into the forming cavity.
 34. A deviceaccording to claim 31, characterized in that each of the petals has atapered end portion converging towards the axis of the mandrel,comprising a radially inner surface tapered in the direction ofpenetration of the male member into the forming cavity.
 35. A deviceaccording to claim 31, characterized in that the forming cavity and thepetals have tapered developments which are complementary with oneanother, tapering taking place in the direction of penetration of themale member into the forming cavity.
 36. A device according to claim 33,characterized in that the shaping means comprise a support and/or thrustmember moving relative to the forming cavity and having an end seatadapted to engage an end head portion of the intermediate packaging. 37.A device according to claim 33, characterized in that it furthercomprises a rod support member adapted to support the central region ofthe intermediate packaging.
 38. A device according to claim 33,characterized in that the mandrel with petals may move axially relativeto the forming cavity between a position spaced from said cavity, inwhich the petals of the mandrel are in an extended configuration able toencompass the container wall of the wrapper and an end position in whichthe end of the petals has penetrated into the forming cavity and thepetals are in a retracted position and further comprising actuator meansadapted to cause the petals to move from the extended position to theretracted position during the movement of penetration of the petals intothe forming cavity.
 39. A device according to claim 38, characterized inthat the actuator means comprise, for each of the petals, a cursormember moving in a slot comprising a sliding section converging towardsthe axis of the mandrel in the direction of penetration of the mandrelinto the forming cavity.
 40. A packaging for a food product wrapped in awrapper comprising a first and a second sheet connected together atrespective counterpart peripheral regions, wherein the second sheetcomprises a planar central region defining a support plane for thewrapper and for the product contained therein with a respectiveperipheral region surrounding said central region so as to form acontainer body with a general cup-shaped configuration, the peripheralregion having respective inner and outer surfaces with respect to saidcup-shaped configuration, and the first sheet defines a reception cavityfor the product and has the respective peripheral region substantiallyextending with and connected to the inner surface of their respectiveperipheral region of said second sheet, characterized in that the planarcentral region of the second sheet has a maximum transverse dimension(or diameter) lower than the maximum transverse dimension (or diameter)of the wrapped product.
 41. A packaging according to claim 40,characterized in that the respective peripheral regions are pleated. 42.A packaging according to claim 40, characterized in that the first andsecond sheets have a coating of thermofusible material at least on themutually facing surfaces of the counterpart peripheral regions.
 43. Apackaging according to claim 40, characterized in that the first and thesecond sheets are formed from sheet materials of different colour.
 44. Apackaging for a food product wrapped in a wrapper comprising a first anda second sheet connected together at respective counterpart peripheralregions, wherein the second sheet comprises a planar central regiondefining a support plane for the wrapper and for the product containedtherein with a respective peripheral region surrounding said centralregion so as to form a container body with a general cup-shapedconfiguration, the peripheral region having respective inner and outersurfaces with respect to said cup-shaped configuration, and the firstsheet defines a reception cavity for the product and has the respectiveperipheral region substantially extending with and connected to theinner surface of their respective peripheral region of said secondsheet, characterized in that the planar central region of the secondsheet has a maximum transverse dimension (or diameter) lower than themaximum transverse dimension (or diameter) of the wrapped product,wherein said packaging is formed by a method according to claim 23.